Structures, assemblies, and methods for controlling vehicle suspension

Abstract

A suspension system for a land vehicle has at least one rear suspension device and at least one front suspension device. The rear suspension device includes a first biasing member disposed within a first housing and is configured for mounting on a rear axle housing of the land vehicle. The front suspension device includes a second biasing member disposed in a second housing and is configured to be at least partially received within a bump stop support of the land vehicle.

1. A suspension system for a land vehicle, the system comprising:
 (a) at least one rear suspension device compressible along an axis, the rear suspension device comprising:
 (i) a rigid first housing comprising a first cavity and a first end surface located in the first cavity; 
 (ii) a first shaft slidably engaging the first cavity; and 
 (iii) a first biasing member comprising a compressible foam located in the cavity between the first end surface and the first shaft, wherein the rear suspension device is configured for mounting on a rear axle housing of the land vehicle; and 
 
 (b) at least one front suspension device including a second biasing member disposed in a second housing, wherein the front suspension device is configured to be at least partially received within a bump stop support of the land vehicle. 
 
     
     
       2. The system of  claim 1 , wherein the land vehicle is an off-road vehicle. 
     
     
       3. The system of  claim 1 , wherein the second biasing member comprises a compressible foam. 
     
     
       4. The system of  claim 1 , wherein the compressible foam is generally a microcellular foam. 
     
     
       5. The system of  claim 1 , wherein the compressible foam is generally a closed cell foam. 
     
     
       6. The system of  claim 1 , wherein the second housing is a second rigid housing comprising a second cavity and a second end surface located in the second cavity, the front suspension device further comprising a second shaft slidably engaging the second cavity, wherein the second biasing member is disposed within the second cavity between the second end surface and the second piston. 
     
     
       7. The system of  claim 1 , wherein the rear suspension device is capable of supporting a load within the range of about 200 lbf to about 4500 lbf. 
     
     
       8. The system of  claim 1 , wherein the front suspension device is capable of supporting a load within the range of about 200 lbf to about 4500 lbf. 
     
     
       9. A suspension device for a land vehicle, comprising:
 (a) a rigid housing comprising a cavity and an end surface located in the cavity; 
 (b) a shaft slidably engaging the cavity; and 
 (c) a compressible foam disposed within the housing between the end surface and a first end of the shaft, wherein the suspension device will support a load within the range of about 200 lbf to about 4500 lbf. 
 
     
     
       10. The suspension device of  claim 9 , wherein a side surface of the cavity provides lateral support to the compressible foam as the compressible foam is compressed. 
     
     
       11. The suspension device of  claim 9 , wherein the compressible foam is compressed between the first end of the shaft and the end surface of the housing when the shaft is biased toward the housing. 
     
     
       12. The suspension device of  claim 9 , wherein the compressible foam provides progressive resistance to the shaft. 
     
     
       13. The suspension device of  claim 12 , wherein the compressible foam is formed to have a contoured profile. 
     
     
       14. The suspension device of  claim 12 , wherein the compressible foam is formed to have a tapered thickness. 
     
     
       15. The suspension device of  claim 9 , further comprising a bump stop positioned on a second end of the shaft. 
     
     
       16. The suspension device of  claim 15 , wherein the suspension device is sized and configured to be mounted to one of a chassis and an axle housing of the land vehicle, the bump stop engaging the other of the chassis and the axle housing to compress the compressible foam when the axle housing moves toward the chassis. 
     
     
       17. A method of providing rear suspension on a land vehicle, the method including:
 (a) obtaining a suspension device comprising:
 (i) a rigid housing comprising a cavity and an end surface located in the cavity; 
 (ii) a shaft slidably engaging the cavity; and 
 (iii) a compressible foam disposed in the housing between the end surface and the shaft, wherein the suspension device will support a load within the range of about 200 lbf to about 4500 lbf; and 
 
 (b) coupling the suspension device to a rear axle housing of the vehicle. 
 
     
     
       18. A method of providing front suspension on a land vehicle, the method including:
 (a) obtaining a suspension device comprising:
 (i) a rigid housing comprising a cavity and an end surface located in the cavity; 
 (ii) a shaft slidably engaging the cavity; and 
 (iii) a compressible foam disposed in the housing between the end surface and the shaft, wherein the suspension device will support a load within the range of about 200 lbf to about 4500 lbf; 
 
 (b) decoupling a factory device from the vehicle chassis; and 
 (c) coupling the suspension device to the vehicle chassis. 
 
     
     
       19. A suspension system for a land vehicle, the system comprising:
 (a) a first suspension device comprising:
 (i) a rigid housing comprising a cavity and an end surface located in the cavity; 
 (ii) a piston slidably disposed within the cavity; and 
 (iii) a compressible foam disposed in the housing between the end surface and the piston, wherein the first suspension device is configured for mounting on a rear axle housing of the land vehicle; and 
 
 (b) a second suspension device, wherein the second suspension device comprises one of a spring and a shock absorber. 
 
     
     
       20. The system of  claim 1 , wherein the compressible foam comprises a cellular polyurethane elastomer.